Karl Phelan - Electrical Lighting Design & Solar Thermal Hot Water Installation

Karl Phelan B00036379

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Karl Phelan B00036379 BN039 BSc in sustainable and electrical control systems 2 John Kilcoyne Mini Project Year 2 Lighting Design / Solar Thermal May 3rd 2011 May 3rd 2011


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Year 2 Mini Project

Year 2 Semester 2

Submitted to

Owen Flood

John Kilcoyne

Lecturer in Sustainable Electrical & Control

Technology

Blanchardstown Institute of Technology

May 3rd 2011

By

Karl Phelan

Student

ITB


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Acknowledgements

I would like to express my gratitude to a number of people who have

gotten me this far in my studies and research.

Firstly I would like to acknowledge the hard work and dedication of the

lecturers in the Institute of Technology, Blanchardstown. They have

shown great patience and have been very active in the development of

this report.

I would like to thank John Kilcoyne and Owen Flood especially for their

help throughout this process. They have worked tirelessly throughout this

semester to motivate and set me on the right track.

The help and support received from Thorlux Lighting in particular

deserves acknowledgement. From my correspondence with their support

staff to the layout of their online webpage, they have been nothing but

obliging and helpful.

I am indebted to several sustainable technologies companies who have

supplied me with the information I’ve needed to compile this report. I

would like to thank Kingspan, Philips, Thorn, Thorlux, Alternative Energy

Ireland to name but a few.

In closing I would like to thank my colleagues in ITB for their help

throughout this report.


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Table of Contents

Title Page

Acknowledgements 3

1.0 Executive Summary 8

2.0 Introduction 11

Section A

3.0 Electrical Lighting Design Installation 12

3.1 Lighting Design per Room 14

3.1.1 Main Show Room 14

3.1.2 Stores 17

3.1.2.1 Hallways 19

3.1.3 Loading Bay 20

3.1.4 Canteen 23

3.1.5 Works Manager’s Office 26

3.1.6 Toilets 28

3.1.7 Reception 30

3.1.8 Electrical Switch Room 31

3.1.9 Main Entrance Hall 32

3.1.9.1 Hallways 34

3.2 Lighting Design Components 36

3.2.1 Solow T5 (Smart) 37

3.2.2 Solow XL (Smart) 39


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3.2.3 Juno 41

3.2.4 XL-Five Prismatic 42

3.2.5 CL-Five 43

3.2.6 Base LED 44

3.2.7 Micro Bloc 45

3.2.8 Jupiter 46

3.2.9 Prismalux 47

3.2.10 Control and Switching Gear 48

3.2.10.1 Light Management System 48

3.2.10.2 Lux Level and PIR Sensors 51

3.2.10.3 Main Showroom/Stores Sensor Spec 53

3.2.10.4 Motionline 54

3.2.11 Wiring 55

3.3 Lighting Design Formula’s and Factors 56

3.3.1 The Lumen Method 57

3.3.2 Utilisation Factor 58

3.3.3 Maintenance Factor 58

3.3.4 Room Index (K) 58

3.3.5 Space Height Ratio 59

3.3.6 Light Output Ratio 59

3.3.7 UF and MF Calculation 60

3.4 Technical Data and Calculations Per Room 61


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3.4.1 Factors Affecting Luminaire Quantities 62

3.4.2 Lumen Output 65

3.4.3 Final Calculations 68

Section B

4.0 Solar Technology 70

4.1 System Components 72

4.1.1 Solar Collectors 73

4.1.2 Solar Cylinder 75

4.1.3 Pipe Work 78

4.1.4 Temperature Sensors 79

4.1.5 Differential Temperature Controller 80

4.1.6 Heat Transfer Fluid 81

4.1.7 Installation & Mounting of Solar System 82

4.1.8 Installation of Pipe Work 83

4.1.9 Flow Meter 84

4.1.10 Expansion Vessel 85

4.1.11 Pressure Gauge 86

4.1.12 Automatic Air Vent 87

4.1.13 Drain Valve 88

4.1.14 Pressure Relief Valve 88

4.1.15 Thermostatic Mixing Valve 89

4.1.16 Non Return Valve 90


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4.1.17 Immersion Heater 91

5.0 Technical Calculations/System Components Sizing 92

5.0.1 Collector Area 93

5.0.2 Hot Water Demand 95

5.0.3 Sizing the Collector Array 97

5.0.4 System Flow Rate 98

5.0.5 Pipe Sizing 99

5.0.6 Pump Sizing 100

5.0.7 Expansion Vessel Sizing 102

6.0 Stagnation Prevention 103

7.0 Working at Height Risk Assessment 106

8.0 References 110

9.0 Technical Drawings 112

9.1 Electrical Plan 113

9.2 Wiring Plan 114

9.3 Sensors Plan 115

9.4 Building Plan 116

9.5 Solar Plan 117

9.6 Solar Cylinder 118

9.7 Close Up View 119

9.8 Side View 120

9.9 Front View 121


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10.0 Appendix A 122

10.1 Thorlux Solow T5 Smart

10.2 Thorlux Solow XL Smart

10.3 Thorlux Juno Exterior

10.4 XL-Five Prismatic

10.5 Thorlux CL-Five

10.6 Thorn Base LED

10.7 Thorlux Micro Bloc

10.8 Thorn Jupiter II

10.9 Thorlux Prismalux

10.10 Solow T5 Presence Detection

10.11 Thorlux Lighting Control Module

10.12 Thorlux LCM POD

10.13 Motionline

10.14 Lamp Data Sheets

10.15 Site Survey

10.16 Installation Checklist

10.17 Thermomax HP200

10.18 Thermomax HP200 Specifications

10.19 AEI Brochure 2009

10.20 Aeroline INOX Classic

10.21


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1.0 Executive Summary

The following report is on Lighting Design and Solar Design Technology.

The report focuses on the components of Lighting and Solar Design and

the calculations and formulas required to undertake such a project.

The report was carried out between January 2011 and May 3rd 2011.

The report was commissioned as part of the Mini Project Module,

Semester 2, Year 2 in the Sustainable Electrical and Control Technology

course in ITB (BN039).

Guidelines for each part of the report were set out at the beginning which

were to be followed.

The report is based on the design of an Electrical Lighting Design and

Solar Thermal Design at a car showroom in Swords, North County Dublin.

The report consists of two sections.

Section A deals with Lighting Design Technology. This section is broken

down into several sub sections which deal with various aspects of Lighting

Design.

A brief introduction is given at the beginning outlining reasons for

sustainable design and financial benefits.

A breakdown is then given about each room. In these breakdowns the

dimensions and factors affecting each room are stated and explained.

In the next section the Luminaires used within this report are broken

down and explained using data from the respective luminaires data sheet.

Details of luminaires used, switching methods, and control methods are

provided and a rationale is given for the use of each. The data sheets for

all luminaires are given in the appendices.


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The last section in the lighting design report outlines the calculations used

in each room with a detailed grid for ease of access. These have been

calculated manually and verified with colleagues.

Section B deals with the Solar Thermal Installation.

Within this section outlines dictated that a solar thermal system was to be

installed within the property in Swords, Co. Dublin.

The parameters given were for a 300 litre solar cylinder to be installed for

a max daily usage of 300 litres per day.

This was a challenging aspect of the report but I enjoyed the research

and learned some new things as I progressed as well as re-enforcing what

I had already learned.

As with the previous section, Section B is layed out in much the same way

as the other.

Part 1 deals with the need for sustainability and the benefits that can be

provided by installing a solar thermal system in one’s property.

Following that each component is discussed and clearly explained with

technical data from the specification sheet of each component.

The Solar Thermal System used in this installation is the Thermomax

HP200. I found this system to fit the needs of the customer best and was

ideal for the task at hand.

Once again all data sheets can be found in the appendix of this report in

Section B.

In the last section of the Solar Thermal report a chapter on Stagnation

Prevention is provided. The dangers of stagnation and how to prevent

such happening is discussed.


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Each section in this report is accompanied by several technical drawing

which can also be found in the Appendices of this report.

This report and its technical data conform to current industry guidelines

and relevant standards.


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2.0 Introduction

The following report is on Lighting Design and Solar Design Technology.

The report focuses on the components of Lighting and Solar Design and

the calculations and formulas required to undertake such a project.

The report was carried out between January 2011 and May 3rd 2011.

The report was commissioned as part of the Mini Project Module,

Semester 2, Year 2 in the Sustainable Electrical and Control Technology

course in ITB (BN039).

The objective of this report was to follow and adhere to the guidelines set

out at the beginning whilst gaining a better understanding of the topics

covered.

The report is divided into several sections.

Section A deals with Sustainable Lighting Design Technologies and the

installation and selection of luminaires, control and switching technology

and also the technical information and calculations used to back up the

installation.

Section B is concerned with the Solar Thermal Installation. The structure

of this section is similar to that of section A.

In part 1 of this section the components of a Solar Installation are

discussed.

Part 2 deals with the calculations used in this installation.

All sections come with technical data sheets and technical drawings which

can be found in the rear of this report.


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3.0 Electrical Lighting Design Installation


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3.0 Lighting Design

Dennis Grange Motors is a business which deals in New and Second hand

Cars sales and imports and servicing.

The client understands that in this environmentally aware society

customers acknowledge and are aware of green technologies and

advances in technology.

Dennis Grange Motors envisages that by having an environmentally

carbon neutral premises that customers will look favourably on their

business and will be prepared to deal with such a business over those who

have not implemented measures to tackle their environmental impact.

They believe that by introducing these measures that it will reflect on the

brand of car they promote and stock.

Apart from business motives, Dennis Grange Motors fully understands the

impact that car emissions have on the environment and are fully

dedicated to tackling these and have requested that their new premises

be fully designed with sustainability in mind.

The client has instructed us to design a sustainable lighting design system

with energy saving measures for a reduced electrical and upkeep cost and

to decrease to businesses carbon footprint.

Apart from energy saving luminaries they have instructed us to install

sustainable control and switching methods.


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3.1.0 Lighting Design

3.1.1 Main Show room

The main room is the focal point of the property and will be the room that

customers will be using the most.

The client has instructed that the room will be used as the Main

Showroom.

As the clients business is mainly car sales and servicing, the main room

must be large, open plan, and bright enough to emphasise the product

(Car Brand etc).

The main room, visible from the outside, has large front facing windows

to allow natural light to enter the room during daylight hours. This will in

turn reduce the need for lighting during these hours and in turn keep

electrical costs to a minimum.

The room itself is of a high bay design with an 8 metre ceiling. The

room dimensions are 15.6x19.44 m2.

The Working Plane is at approx 1 metre.

The CIBSE guide recommends that this room be illuminated to a lux level

of 500 Lux as show room sales and general car servicing takes place.

This means colour judgement may be required on electrical cable etc.

Good colour rendering is essential.

The Utilisation Factor for this room is 0.6 as the luminaire is quite good

but is at a height and there are a lot of windows.

The Maintenance Factor in this room is 0.6 also as it is a relatively

clean room but as mentioned before general car servicing takes place

also.


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The luminaries selected for this room are the Thorlux Solow T5 Smart

4x54W by Thorlux.

This was selected as it incorporates smart switching and lux

level/occupancy sensors pre-fitted.

They will be installed on metal trunking supported by roof beams.

24 luminaries will be sufficient to light this room. (Calculations in

section 1.3.)

The version selected has a polycarbonate cover and smart switching pre

installed.

Below is a sample of a similar set up.


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3.1.2 Stores

The stores room is the second largest room within the building.

As the name suggests, this room will be used to keep files and car parts.

A small part of the room will be partitioned to hold the Solar Thermal Hot

Water Storage Cylinder which we will be introducing later in this report.

This will not affect the lighting design installation.

The stores room has a ceiling height of 4 meters. The room dimension is

approximately 68.2m2.

The Working Plane is at 1 metre.

As there is little light in this room due to it having only one external wall a

bright illuminance is required.

The recommended lux level for this room is 150 Lux

The Utilisation Factor in this room is 0.6 as the walls, ceilings, and

floors are of a dark shade as the stores aren’t for customer use.

The Maintenance Factor is 0.5 as old car parts and spares are kept

here alongside the file stores.

The luminaire selected for this room is the Thorlux SolowXL Smart

(T5) 4x49W by Thorlux. This was selected for its smart switching and

lux level sensors and also for its energy saving abilities and because its


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target illuminance is 150 lux at floor level which is what is needed.

With these figures we have calculated that 4 luminaries are required to

sufficiently illuminate this room.


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1.1.2.1 Hallways

There is a small hallway dividing the stores from the outside loading bay

that allows access from the hallway into the showroom.

As you will see in section 1.1.9 we will be using The Thorn Base LED

luminaire to light up the hallway areas.

This hallway is no different.

The hallway is 10.36m2 with a ceiling height of 2.4m.

The working plane is at ground level.

The recommended Lux Level for a hallway is 100lx but as the hallways

will be used by customer traffic we have set a Lux Level of 200lx.

Lux Level: 200lx

MF: 0.7

UF: 0.7

We have calculated that 7 luminaries are sufficient for this hallway.


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3.1.3 Loading Bay

The loading bay is to the front of the building to the right of the double

doors of the main entrance.

The loading bay is used to bring cars into the main showroom and service

area. There is a large sliding factory shutter to allow entry and exit for

large vehicles.

The loading bay has no shelter and has no partition wall surrounding it.

The plan of the building shows that the loading bay extends out to cover

40.34 m2 from the sliding shutter to the double doors of the main

entrance. Working Plane is 1 metre.

The recommended lux level, given by the CIBSE guide, for this area is

150 Lux.

The Utilisation Factor for this area is assumed to be 0.6 as lighting will

not be required during daylight hours (excluding Winter) and there are

several street lamps surrounding the loading area.

The Maintenance Factor is determined to be 0.5 as the loading bay is

outdoors and is frequently used by motor vehicles and mechanics.

The Luminaire selected for this area is the Juno Exterior Light 100W

(LMP 9748) SON-T Plus by Thorlux.

Lux level sensors will be installed in the Loading Bay.

Two luminaries are required to illuminate this area.


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This luminaire was selected for its low light pollution and integral control

gear.

It is to be erected on a twin pole set-up in the middle of the loading bay.

Below is an example of a similar set-up.


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3.1.4 Canteen

The canteen is a general staff area. Food is cooked, stored, and consumed

here.

The canteen contains a cooker, sink, microwave and fridge. Several tables

and seats are also located in the canteen for staff leisure.

The canteen is approx 13.71m2. The ceiling height is 2.4m tile. The

Working Plane is at 0.75 metres.

The CIBSE guide recommends a lux level of 300 lux for canteens and 500

lux for kitchens. Bearing that in mind a lux level of 400 Lux has been

selected for this room.

The Maintenance Factor for this room is 0.6 as it is kept relatively clean

but food is also consumed in this location.

The Utilisation Factor for this room is 0.7 as the interiors are painted a

light shade of white with a plastic glazed chipboard countertop.

The Luminaire selected for this room is the Thorlux XL-Five Prismatic

Smart 4x14W (T5).

3 Luminaries will be sufficient for the canteen.

As there is no external windows located in the canteen an occupancy

sensor will be sufficient for control and switching.

This luminaire was selected for its vibrant yet simplistic appearance and

low power usage.


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3.1.5 Works Managers Office

The works manager’s office is the smallest room in the building. It is

located through the main entrance doors to the second door on the right.

The Manager of this Dennis Grange Motors branch will be located here.

The room is 5.95m2 in size and contains one desk with a computer. The

ceiling is 2.4m high tiled. The Working Plane is at 0.75 metres. There

are two filing cabinets placed alongside the wall.

The recommended Lux level for this room is 500 Lux as it is used as a

general office.

The Utilisation Factor in this room is 0.6. The room is decorated with

dark colours with low reflectance and a carpeted surface.

The Maintenance Factor is also assumed to be 0.6 as the room is

carpeted and quite small.

The Luminaire selected for this room is the Thorlux Surface Mounted

CL-Five 2x14W (T5).

A smart version of this luminaire was not used because the smallest lamp

fitting available for that version would illuminate the room to an extra-

ordinary level.

An occupancy sensor will be sufficient as switching gear for this room.

4 Luminaries have been calculated to illuminate this room sufficiently.


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3.1.6 Toilets

The toilets are located at the south end of the property. There are two

separate rooms for both male and female patrons of the building.

In each toilet there are three cubicles two sinks and a large mirror. There

is also a hand dryer and towel dispenser.

The toilets are 10.2m2 each which brings the total combined area of both

toilets to 20.4m2.

For the purpose of lighting design we will take each room as a separate

entity.

The toilets both have a small lobby preceding them. A small Microdot

fitting will be installed in each of these.

Each toilet has a 2.4m high ceiling and a working plane of 0.75m

The recommended Lux Level for toilets is 100 Lux.

The Maintenance Factor in the toilets is 0.6. The toilets are regularly

cleaned by a dedicated maintenance staff member.

The Utilisation Factor of both rooms is 0.6. This is because the toilets

are decorated with a green ceramic tile finish.

The luminaries selected for the toilets are the Thorlux Micro Block 16W

2D fittings. Calculations state that 3 luminaries should be adequate to

sufficiently illuminate each of the toilets, both male and female.

Occupancy sensors will be installed in both male and female toilets.


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3.1.7 Reception

The Reception is located to the immediate left as you walk through the

entrance doors.

The entrance is 6.9m2 in size and has a working plane of 0.75m.

The ceiling height is 2.4m.

The recommended Lux Level for the reception area is 300 Lx.

The Maintenance Factor for the reception area is 0.6. The reception is

kept moderately clean as it is a focal point in the property.

The Utilisation Factor is set at 0.6 also. This is because the room is

painted with a glossy bright peach colour.

The luminaire

selected for this

room is the Thorn

Jupiter II 1x28W

(T16).

The Reception will

be fitted with a

combined

occupancy sensor

and lux level

sensor.


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3.1.8 Electrical Switch Room

The Electrical Switch Room is located in the main entrance hall. The

Switch room is the centre for all electrical connections, safety devices,

breakers etc. The control centre for the lighting system is also located in

this room.

The room is 3.6m2 with a ceiling height of 2.4m.

The working plane in the switch room is between 1.0m and 1.2 m.

The recommended Lux Level for the Electrical Switch Room is 150lx.

The Maintenance Factor in the switch room is 0.7 as the room is kept

relatively clean and free of obstacles for ease of access.

The Utilisation Factor in the switch room is 0.6 because of its small size

and the nature of the room.

The luminaire selected for this room is the Thorlux Prismalux 26W TC-

T.

The lamp was selected for its low power load and high colour rendering

ability @3500K. This will benefit any technicians working in the switch

room.

No sensors will be

installed in this

set up.


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3.1.9 Main Entrance Hall

The Main Entrance Hall will be the first point of access for most customers

and as such should be treated as a first impression.

Dennis Grange Motors will be providing refreshments and meeting

stations for its customers and employees for discussions in this area.

For this reason the lighting level

must be sufficient and visually

pleasing to the customers. It

must also allow them to read

documents and view pictures

with ease. The colour rendering

of the lamp selected below is

sufficient for these requirements.

The room itself has an area of

13.51m2 and a ceiling height of

2.4m tiled.

The working plane is about 0.75m also.

According to the CIBSE guide the

recommended Lux Level in this area is

200lx.

The hall is kept clean because of its

purpose and is maintained daily by

dedicated support staff.

For this reason the Maintenance

Factor for the Hall is 0.7


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The Utilisation Factor for the Hall is also 0.7. The decor is a bright

colour and there are two windows allowing light into the room.

The selected luminaries for the Entrance Hall are the Thorn Base LED.

The lamp selected for this fitting is the BaseLED 165 MRE 1X12W LED

L927. It has a colour rendering of 3500K.

Calculations have shown that 10 Luminaries are sufficient for the

Entrance Hall.


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3.1.9.1 Hallways

The hallways adjoin the Main Entrance to the right of the switch room.

They must be lit sufficiently for patrons and staff to navigate with ease.

As the hallways are a continuation of the main entrance the parameters

for lighting design will not be changing.

The ceiling is 2.4m. There are 2 sections of the hallway to take into

account.

Section 1:

This section is 5.5m2 in size and has a tiled ceiling.

UF: 0.7

MF: 0.7

Recommended Lux Level: 200lx

Section 2:

This section is 3.75m2 in size and has a tiled ceiling.

UF: 0.7

MF: 0.7

Recommended Lux Level: 200lx

As the parameters are the same as the main entrance it is only logical to

select the same luminaire and lamp fittings for this area also.


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In Section 1:

We will be required to install 4 Thorn Base LED luminaries with the lamp

selected for this fitting to be BaseLED 165 MRE 1X12W LED L927.

In Section 2:

As with Section 1 we will be using Thorn Base LED’s with the BaseLED

165 MRE 1X12W LED L927 lamp.

For this section we will require 3 luminaries.


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3.2 Lighting Design Components


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3.2.1 Solow T5 Smart

The Solow T5 Smart was chose for this installation simply because it was

head and shoulder above the rest during design selection.

The high bay luminaire makes it perfect for the large showroom and was

perfect for what the client was looking for.

The unique design of this luminaire provides excellent illumination even

up to 10 metres.

With a mounting height of 8 metres in mind we quickly decided this was

the best choice.

The smart version of the Solow T5 encompasses its own smart pod. The

smart pod is an intelligent programmable lighting controller.

It provides maintained illuminance, daylight linking, PIR control, and

infra-red remote control.

The Solow range is a very efficient energy saver and is highly efficient.

The range when coupled with the smart system can achieve an electrical

load of 70% of a client’s annual load. That’s a saving of 70%.

In this installation the Solow T5 Smart luminaries will be surface mounted

to the re-enforced trunking at 8 metres high.

This will be sufficient to allow to occupancy and lux level sensors to

operate with negligible hassle.

The luminaries will be connected to one another using a “Motionline” two-

core low voltage bus. This will allow each luminaire to respond

simultaneously when movement is detected or lux level change is

triggered.


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3.2.2 SolowXL Smart

The SolowXL Smart Luminaire was selected for this installation for a

number of reasons.

The SolowXL is a high performance

luminaire with a high performance

arc. The sheer minimal size and

weight of this luminaire provides

benefits straight away.

It can provide either a broad or

narrow light distribution with output

ratios of up to 97%. There are numerous mounting options available with

this luminaire for varying low or high bay applications.

This SolowXL comes with an integrated micro pod sensor which will

control the light level and detects occupancy(Lux Level and Occupancy

level sensors). As mentioned for the Solow T5, the Solow range alone can

achieve savings of up to 70%

The luminaire can be mounted up to a height of 10m and has options for

emergency and autotest features. This includes both suspension and

surface mounting.

There is an option for an uplighting attachment if required.

As with the Solow T5 Smart this luminaire will be surface mounted to

busbar trunking and connected using Motionline to improve efficiency.


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The client has specified that savings are a priority and with this luminaire

the client’s expectations can be achieved and surpassed.

Observe the following case study.


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3.2.3 Thorlux Juno

The loading bay caused a challenge as it outdoors and is not sheltered.

Due to the nature of the client’s business it is essential that the loading

bay be illuminated; not only for safety reasons but for illumination of the

brand. In sales, the brand must always be seen, and Dennis Grange

Motors is no different.

The Thorlux Juno was selected for the Loading Bay because it fits suitably

to what the client needs.

It has:

Zero Upward Pollution

Corrosive Resistant Cover

Flat Toughened Safety Glass

Integrated Control Gear

Installation of the Juno Luminaire will be

done using a twin pole mount.

A 100W SON-T Plus (LMP9748 Thorlux Catalogue) lamp will be used in

the installation.

The luminaries will be installed at an 8 metre height.


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3.2.4 Thorlux XL-Five Prismatic

The XL-Five Prismatic was chosen for the canteen because its shallow

65mm body will fit perfectly into the tiled ceiling.

The XL-Five Prismatic comes with a steel body finished white which will fit

aesthetically with the decoration in the canteen.

The smart version come with a side arm suspension kit and is fitted with

3500K lamps.

It will fit a square tile perfectly with its 600x600mm size.

A colour render of 3500K will promote a relaxed atmosphere to the staff.

The lamp chosen to fit this luminaire is the 14W T5 lamp (Cat No. LMP

10139).

The smart version comes equipped with an occupancy and lux level

sensor as standard.

Installation Guide in appendices.


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3.2.5 Thorlux CL-Five

The Thorlux CL-Five luminaire was selected for the manager’s office.

This was chosen for a number of reasons.

Firstly the manager’s office is quite small.

Heavy load bearing lamp/luminaire wouldn’t fit with the criteria for energy

savings.

The luminaire has high frequency regulating control gear as standard.

The Smart version was not selected as the lumen output of the smart

version well exceeded what is required to sufficiently light up the

manager’s office.

The luminaire has a perforated body which creates soft modelling. This

helps the luminaire to fit into the natural decor of the room without

standing out.

The luminaire is 600x250mm in size and can support up to 3 T5 lamps.

The product selected for the office will be the 2x14W T5 LG7:2005

version.


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3.2.6 Thorn Base LED

The Thorn Base LED was selected for the Main Entrance Hallway and also

used in the other two hallways.

This downlighter was selected for its unprecedented LED lighting

performance and excellent colour rendering. Colour rendering is essential

for the client as his business is in sales. As

mentioned before the product must always be

seen to the best of ability.

The Base LED has brilliant colour rendering

(3500K) and its diffuser controls glare and

according to the data sheet even light.

The Base LED consumes an average of 12W.

Energy usage can be cut by up to 75% compared to an 18W compact

fluorescent and 50W halogen mains

downligters.

The diffuser gives a wide, soft beam with

equally good vertical and horizontal

illuminance.

The Base LED luminaire is being used with a

BaseLED 165 MRE 1X12W LED L927 lamp and

will be recessed within the tiling.

Several rooms within the property will be using this luminaire/lamp set-

up.


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3.2.7 Thorlux Micro Block

The Thorn MicroBlock was mainly chosen because of its suitability for use

in toilet areas and damp areas.

The luminaire is IP43 rated, is fire resistant and as mentioned can

withstand damp and wet areas.

This makes its suitable for use in the toilets.

The lamp being used is the 16W 2D produced by GE. (LMP 7333)

The luminaire is 217x217mm in size.


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3.2.8 Thorn Jupiter

The Thorn Jupiter II was selected to be installed in the Reception area for

its low power consumption of 31W.

The Jupiter II is IP20 rated, fire resistant and rated up to 850° Celsius.

The Jupiter II provides a broad,

extended, horizontal and

vertical illuminance.

Mounting options for this

luminaire include surface

mounting and suspended

mounting.

Keyhole slots are provided for

fixings.

The lamp selected for this luminaire is the 28W T16 manufactured by GE.


49

3.2.9 Thorlux Prismalux

The luminaire (Thorlux Prismalux) selected is a heavy duty bulkhead

fixture. It was selected for this installation to be placed in the Electrical

Switch Room.

It was selected because of its robust and strongly framed body.

The Prismalux is IP65 rated and is flame and water resistant.

The Prismalux is ideal for industrial areas, power stations, cable tunnels,

and pump rooms because of its reinforced body.

Several lamp variations can be installed within the luminaire giving the

client and installer a varied choice. The range of lamps catered for include

GLS, SON, MBF and TC-F.

The lamp selected for this installation is the 26W TC-T 1800lm output with

a high colour render of 3500K. (LMP 11555)

The colour render provides

technicians with a brightly lit

working area for any maintenance

carried out in the switch room.


50

3.2.10 Control and Switching Gear

3.2.10.1 Light Management System

The Thorlux Lighting Control Module and LCM Receiver have been

selected to be installed for the client.

The Thorlux LCM system allows the user to combine the LCM modules

with other lighting components through a plug and socket wiring system.

Up to 20 luminaries can be connected to each LCM System although the

LCM-POD (shown below) can be common to several LCM systems.

Up to 100 LCM systems can be connected together and can also be

connected to a Building Management System.

The system allows for a simplified or complex layout. The LCM system is

also very flexible and will allow for future layout changes.

The LCM system can significantly reduce labour

costs as the luminaries are simply plugged

together.

The LCM control the timed dimming and switching of connected

luminaries by reacting to the signals sent to it by the peripheral

components such as the PIR, Lux Level and Infra-Red sensors.


51

The switching cycle is programmed for a 22 minute time delay while using

PIR control. The lights will dim after 14 minutes if no movement is

detected.

A Typical Set-up is shown on the next page.

(Image courtesy of Thorlux – lighting_control_module_and_receiver.pdf

(appendices))


52


53

3.2.10.2 Lux Level and PIR Sensors

Unless otherwise stated all rooms will be fitted with a PIR sensor. The

product selected to be installed throughout the building is the Thorlux

LCM-POD.

Many of the Luminaries selected come pre-fitted with PIR and occupancy

sensors. The LCM-POD will be installed alongside any luminaire which

does not have this feature pre-fitted.

The LCM POD comes equipped with an Intelligent PIR system, a

Daylight Sensor and also an Infra-Red sensor.

The PIR system has a detection range of 2 metres when mounted at a

height of 2.7 metres. As the sensors will be mounted at 2.4m height

this should be sufficient to

pick up movement within any

of the rooms, excluding the

high bay main showroom and

stores room.

The sensor is very sensitive

even to small movements

such as hand movements.

An intelligent microprocessor provides protection against false triggers

and has an automatic sensitivity and time delay adjustment.

The Daylight Sensor has a sensitive photocell that offers automatic light

level control through maintained illuminance/daylight control. It can be

set from between 20-2000 Lux and can be remotely set using the

Daylight Sensor Transmitter.

The Infra-Red Receiver provides the option to override the Daylight

Sensor at any time.


54

There are 3 preset options available which will set the light level to the

following accordingly.

1. Minimum Light Level

2. 50% Light Level

3. Maximum Light Level

Only one LCM-POD may be connected to each Lighting Control Module. If

improved PIR coverage is required Thorlux can provide addition LCM-

Sensors.

The sensors are easy to install and are designed for semi-recessing.

No mains supply is required as a low voltage connection will suffice

through an RJ45 data lead.

Each room with this system in place will have its own Daylight Sensor

Transmitter and Infra-Red ECO remote transmitter for manual lighting

control.


55

3.2.10.3 Main Showroom and Stores Sensors Specification

The Main Showroom and the Stores Area both have a higher ceiling height

than the rest of the building. Conventional LCM-POD sensors will not be

able to work to their optimal potential as they have a restricted height

limit of 2.7m

The combat this, smart luminaries have been installed in each room.

These luminaries have PIR sensors that will work up to a height of 10m.

In the Main Showroom the Solow T5 (Smart) has been installed while in

the Stores Area the SolowXL Smart has been installed.

These smart luminaries are designed for height and the pre-fitted sensor

can compensate for this.

Please find below a detailed image of the workings of those sensors from

the Thorlux Installation Guide.


56

3.2.10.4 Motionline

In both the Main Showroom and the Stores Area Motionline Technology

will be used.

Motionline Technology links together individual smart luminaries into a

grouped system. A two wire low voltage bus allows the luminaries to

communicate as a group.

This will allow all luminaries connected to this group to respond

simultaneously to any detections made by the sensors such as a

movement in the sensors vicinity.

Because all smart

luminaries have PIR

sensors, this provides

complete PIR coverage

of the floor space in the

room which the

luminaries are to be

installed.


57

3.2.11 Wiring

All wiring within

this installation

was done with

1.5mm 3 core

flex cable with a

10 amp rating

unless otherwise

stated. Cables

from the Main

Showroom have been grouped together as is shown on the technical

drawing.


58

3.3.0 Lighting Design Formula’s and

Factors


59

3.3.1 The Lumen Method

The Lumen Method is used to calculate the number of Luminaries required

to provide a maintained illuminance throughout a room.

The quantity of lumens reaching the working plane is the main factor to

be considered when undertaking a lighting design project.

This light is known as an illuminance which is measured in lux.

The formula below is a form of the Lumen method.

Where,

E= The Maintained Illuminance

F= The initial Lumen Output

N= Number of Luminaries

n= Number of lamps in each luminaire

UF= Utilisation Factor

MF= Maintenance Factor


60

3.3.2 Utilisation Factor

The amount of lumens emitted from a lamp that reach and are utilised by

the working plane is known as the Utilisation Factor.

This value would depend on a certain number of factors including room

reflectance’s, room dimensions, the light output ratio of the fitting and

several others including:

Type of Luminaire

Size and Number of Windows

And also the mounting height of Luminaries.

3.3.3 Maintenance Factor

The maintenance factor gives an estimate of how lighting conditions will

deteriorate through use.

It refers to the illuminance give out by a lamp under certain conditions.

Such conditions include those as under a dirty environment or if a lamp is

aged as opposed to a clean environment or a newly installed lamp.

3.3.4 Room Index(K)

The Room Index (K) is the ratio of a room plan area to half the wall area

set between the working plane and the mounting height of the luminaire.

Where,

L= Length of Room

W= Width of Room

Hm= Distance between the Mounting Height of Luminaire – the Working

Plane of the room.


61

3.3.5 Space Height Ratio

The Space Height Ratio (SHR) refers to the even distribution of luminaries

in a room. It is the ratio of the centre to centre distance between adjacent

luminaires to their height above the working plane. It is basically used to

determine if the spacing used is uniform.

The formula used is

Where,

A= Total Floor Area

N= Number of Luminaires

Hm= Mounting Height of Luminaires

3.3.6 Light Output Ratio

The LOR refers to the effectiveness of a luminaire in transmitting the light

from the lamp into the environment.


62

3.3.7 UF and MF Calculation

This find out the total number of lumens that reach the working plane we

must first do several calculations.

The Utilisation Factor must be worked out. This is done by first calculating

the Room Index (K). The formula for K is shown on a previous page.

Using the utilisation factor, maintenance factor, room dimensions, and

finally the recommended lux level, we can then calculate how many

lumens are required and in turn the amount of luminaires.

Below is a worked example.

Works Manager’s Office:

Room Index:

The Manager’s Office has reflectance’s of 7,5,2

Ceiling=7, Walls=5, Floors=2

From the Thorlux Utilisation Tables we can see this corresponds to a 0.6

utilisation factor.

The Maintenance Factor is determined by how clean the room is. Tables

(Appendices) show that the works manager’s office has a maintenance

factor of 0.6.

The recommended lux level in this room is 500lx.

The Lumen Method can now be used.


63

3.4.0 Technical Data and Calculations

Per Room


64

3.4.1 Factors Affecting Luminaire Quantities

The tables below represent the following

The Area of All Rooms

The Recommended Lux Level as per the CIBSE Guide

The Maintenance Factor for each room

The Utilisation Factor for each room

The tables have been created so we can easily present to the reader the

step by step process to determine the quantity of luminaries to be

installed in each room.

Location Lenght Width

Area

(m2)

R. Lux

Lvl MF UF

Showroom 500 0.6 0.6

Area 1 19.44 15.6 303.264


Area

(m2)

R. Lux

Lvl MF UF

Stores 150 0.5 0.6

Area 1 8.04 4.643 37.32972

Area 2 7.283 4.34 31.60822

Total 68.93794


Area

(m2)

R. Lux

Lvl MF UF

Loading Bay 150 0.5 0.6

Area 1 7.203 5.6 40.3368

Location Lenght Width Area R. Lux MF UF


65

(m2) Lvl

Canteen 400 0.6 0.7

Area 1 5.44 2.52 13.7088


Area

(m2)

R. Lux

Lvl MF UF

Works Office 500 0.6 0.6

Area 1 2.52 2.36 5.9472


Area

(m2)

R. Lux

Lvl MF UF

Main

Entrance 100 0.6 0.6

Area 1 3.365 2.077 6.989105

Area 2 3.277 1.915 6.275455

Total 13.26456


Area

(m2)

R. Lux

Lvl MF UF

Toilets 100 0.6 0.6

Men 4.75 2.14 10.165

Women 4.75 2.14 10.165

Total 20.33


Area

(m2)

R. Lux

Lvl MF UF

Reception 300 0.6 0.6

Area 1 2.76 2.5 6.9


66


Area

(m2)

R. Lux

Lvl MF UF

Switch Room 150 0.7 0.6

Area 1 3.365 1.08 3.6342


Area

(m2)

R. Lux

Lvl MF UF

Hallways 100 0.6 0.6

Area 1 5.52 1 5.52

Area 2 2.45 1.52 3.724

Area 3 7.403 1.44 10.66032

Total 19.90432


67

3.4.2 Lumen Output

The tables below show a rough estimation of the lumen output required

per room.

Legend:

E – Lux Level

A – Area

U – Utilisation Factor

M – Maintenance Factor

E A U M

Lux Level x

Area UF x MF Lumen Output

Showroom

Area 1 500 303.264 0.6 0.6 151632 0.36 421200

Location

Stores

Area 1 37.32972

Area 2 31.60822

Total 150 68.93794 0.6 0.5 10340.691 0.3 34468.97

Location

Loading Bay

Area 1 150 40.3368 0.6 0.5 6050.52 0.3 20168.4


68

Location

Canteen

Area 1 400 13.7088 0.7 0.6 5483.52 0.42 13056

Location

Works Office

Area 1 500 5.9472 0.6 0.6 2973.6 0.36 8260

Location

Main

Entrance

Area 1 6.989105

Area 2 6.275455

Total 200 13.26456 0.7 0.7 2652.912 0.49 5414.106122

Location

Toilets

Men 10.165

Women 10.165

Total 100 20.33 0.6 0.6 2033 0.36 5647.222222

Location

Reception

Area 1 300 6.9 0.6 0.6 2070 0.36 5750

Location

Switch Room

Area 1 150 3.6342 0.6 0.7 545.13 0.42 1297.928571


69

Location

Hallways

Area 1 5.52

Area 2 3.724

Area 3 10.66032

Total 100 19.90432 0.6 0.6 1990.432 0.36 5528.977778

The final figure “lumen output” is what is required to illuminate each room

to its required level.

The following table outlines which luminaires and lamps were selected

respective of each room


70

3.4.3 Final Calculations


71

SECTION B

Solar Thermal Installation


72

4.0 Solar Technology

The world we live in is fast running out of what we call fossil fuels. We can

no longer rely on these fuels to power our lives, homes, and businesses.

The sun, our closest star has an infinite source of energy that is just

waiting to be tapped.

It is a widely believed myth that Ireland is not an ideal place to harness

the sun’s energy. This is, as i said before, a myth. Ireland itself harnesses

roughly around 60% of the sun’s energy as any region on the equatorial

belt does.

Although in saying that, we harness this energy mostly between the

months of April – September, with 70% of the energy received by Ireland

being harness able at this time. In fact about 25% of this energy is

received in the months of June and July.

As we use more and more of solar energy to replace more conventional

fuels we are reducing carbon emissions and promoting green energy at

the same time. This can lead to reduced electrical bills and also reduces

each and every citizen’s carbon footprint.

There are several types of solar technology that can be harnessed for

different applications.

Photovoltaic

Active Solar

Passive Solar


73

The most commonly used application of solar technology is active solar

technology.

Active solar technology used solar collectors to trap the irradiance from

the sun. This can then be used to heat fluid water heating systems and

for spatial heating systems.

The benefits of using solar thermal systems are limitless. If a system is

correctly sized and efficiently installed; close to 60% of a residential or

businesses heating requirements per annum can be obtained from using a

solar thermal system.

In fact during the summer months roughly 100% of the requirements can

be met on a daily basis.

Solar collectors are very efficient and can convert both direct and indirect

(diffuse) sunlight into usable energy and heat. This is true even with

overcast weather conditions.

On a side note; as only 30% of Ireland’s solar irradiance is obtainable

during the summer months it is advisable to have a backup system in

place for such times.

The client Dennis Grange Motors understands the potential savings and to

a more subtle extent the message that using such technology portrays

about the brand of car it stocks to his customer base. The building the

client occupies was built with a passive solar design and also with an

active solar thermal system build in.

It was designed to supply a maximum of 300 litres per day to the client

and his customers.

The system selected was an evacuated tube heat pipe collector

arrangement with a dual coil cylinder.

Further details, such as sizing, components and connectors will be

discussed at a later time.


74

4.1 System Components


75

4.1.1 Solar Collectors

The solar collector array is the first point of contact and the main

component of the Solar Thermal System.

The sun’s energy is collected here and is transferred in the form of heat

through the transfer fluid and heat exchanger. This is transferred to the

hot water cylinder.

There are two types of solar collector that

can be used to harness the suns energy.

They are:

Flat Plate Solar Collector

Evacuated Tube Solar Collector

The type of

collector used by the client is an evacuated

tube solar collector. The reason that this type

has been chose is the ease of installation over

the heavier flat plate and the efficiency of using

the tubes over the flat plate collectors.

The Thermomax Heat Pipe Collector HP200

System has been chosen as it is a well

established system and is known to be an

efficient and reliable system. It is designed for

Northern European climates as it provides heat

even in cold, windy and humid conditions.

The Thermomax HP200 System comes with a 5


76

year standard warranty, will supply 70% of the clients water needs and is

30% more efficient than a flat plate collector system.

The HP200 system has a unique feature in that it has a Temperature

Limitation Device. The Temp Limitation Device has a snap disk to

limit temperature to 135 Degrees Celsius for commercial installations and

95 Degrees Celsius for domestic installations.

The Temperature limitation device is fitted in the condenser bulb of the

HP200 System.

The collector utilises a plug and play style design for an

easy installation and for later additions.

The System itself will be placed on the south facade of the building facing

south with an inclination of 37.4°. An awning roof kit (Product Number

KSK0018) will be used to anchor the system to the roof. This particular

bracket was chosen because the building is located in a high wind load

area and as the bracket will be placed at a height the extra protection is

necessary.

HP200 Tube


77

4.1.2 Solar Cylinder

The cylinder that will be used in this installation will be the AEI 300 litre

stainless steel dual coil solar cylinder. This cylinder is ideal for the HP200

system being installed for Dennis Grange Motors as it has a capacity for

300 litres, as is required, it will fit an in-direct system, and it is designed

for a solar thermal designed system.

The AEI 300 Litre is ideal for this clients needs as it is tall and slim which

will fit nicely into the desired location which is a partitioned room in the

stores area. The cylinder itself is made from a high (duplex) grade

stainless steel. This is better than the standard 316 grade and hugely

superior than the 304 grade steel.

The cylinder also comes with a 25 year warranty, as standard, subject to

it being reasonably maintained.


78

The cylinders are rated to 6 bar which is more than enough to cover

mains pressure in any part of Ireland. For added peace of mind the AEI

300 Litre is tested to 9 bar before being delivered.

The AEI 300 Litre Stainless Steel model is fitted with the following:

Factor fitted temperature stats

2 port valves (Central Heating Control)

Expansion Vessel

A Pressure Reducing Set and Tun Dish

The AEI 300 litre Stainless Steel Cylinder will also come pre plumbed and

pre insulated.


79


80

4.1.3 Pipe work

Pipes are used to provide a path to and from the collector to the cylinder.

This is how the heat transfer fluid is circulated throughout the system.

The fluid in the pipes can reach temperatures upwards of 170° Celsius

(Max 135° with this HP200 System) so plastic pipes are not

recommended.

Aeroline® INOX Classic 22 is to be used in this installation. The INOX

classic brand is a pre-insulated twin tube system. It will come pre

insulated with 2x corrugated stainless steel tubes (Flow and Return).

The pipe work is UV resistant and has a silicone temperature sensor line.

The Image above clearly shows the EPDM insulations enclosing the flow

and return paths to the array. We can also see silicone temp sensor line.


81

4.1.4 Temperature Sensors

A temperature sensor will be installed at both the collector and at the

storage cylinder. These will both be connected to the differential

temperature controller located in the house. This will regulate the

temperature according to the readings by controlling the circulating

pump.

The picture on the left shows the

temperature sensor line which will

enable the temperature sensors

(shown below) to determine the

need for the circulating pump being

activated or not.


82

4.1.5 Differential Temperature Controller

As mentioned above, the Differential Temperature Controller has two

sensors. One is located at the pre-heat cylinder and one located by the

solar collector.

The DTC will cause the pump to activate if the temperature on the

collector sensor exceeds the cylinder sensor by a pre set level. The

temperature differential is adjustable on the DTC controller and will

usually have a differential of between 1°-12°celsius. Although, in saying

that, a normal system will have a setting of between 4°-8° Celsius.

The pump will switch off when the DTC reads that the temperature

differential has fallen between the collector and the cylinder.

There are safety measure in place to ensure that the pump does not

switch on and off repeatedly within short intervals (Hunting).

It is usually set for a 2 minute delay and for this installation we will go by

this recommended time span.

For practicable purposes the client will be using the Thermomax SC100

DTC controller. The SC100 is equipped with a newly developed illuminated

display with system monitoring.


83

4.1.6 Heat Transfer Fluid

The Heat Transfer Fluid transfers the heat from the solar thermal

collectors to the water in the cylinder.

The fluid is pumped around the system and will not come into contact

with any water which is destined for human use or consumption.

The pump will circulate the fluid around the system from the solar

collectors down to the cylinder for heating of the water.

There are several solutions available to use in the solar thermal system. It

has been decided that Tyfocor will be used in this system.

Tyfocor can be used at temperatures of up to 170° Celsius. The safety

feature of the HP200 system means that this temperature will not be

reached and it should not be a worry.


84

4.1.7 Installation and mounting of the solar system.

The Thermomax HP200 system can be installed in a variety of ways.

These are shown below on the image.

The mounting option we have chosen to use is KSK0018 Awning Roof Kit.

As we can see from the image above this is suitable for the Heat Pipe

System we are installing. It will be placed on the south wall facing in a

southerly direction with an angle of inclination at 37.4°S.

The recommended angle of inclination for the geographic location of

Dublin is 37.4°. This justifies the angle of inclination that we have chosen

for this client.

A technical drawing of this installation will be available in the appendices

section of this report.


85

4.1.8 Installation of pipe work.

The Solar Collector will be placed on an awning roof kit which will be

placed on the south facade of the building. As it will be placed outdoors it

will be necessary to penetrate the wall to fit the Aeroline pipe work.

In order to cause minimum damage to the property of Dennis Grange

Motors it will be necessary to use small bore holes that are sealed for

protection of heat and from the elements.

For this we will be using Link-Seal® Modular Seal. The seal itself has a:

Long life guarantee

Protects against corrosion

Temperature Resistant

Can fit any size of pipe


86

4.1.9 Flow Meter

The flow meter is used to gauge and control the rate of flow for the heat

transfer fluid. It is possible to control the flow of the fluid by using the

valves on the flow meter. The flow meter is usually located within the

pump station.

Sample Flow Meter


87

2.1.10 Expansion Vessel

The expansion vessel is used to absorb the volume increase of the heat

transfer fluid mix in the pressurised circuit as the temperature in the

circuit increases.

By using an expansion vessel in the system we can ensure that no

damage will be done to the circuit or the solar thermal system as a whole

as the increased volume can be contained in the vessel.

The expansion vessel is basically a large tank that is fitted with an

internal diaphragm.

One side of the vessel is connected to the circuit itself which contains the

water while the opposite side is basically full of air under pressure. There

is a valve to allow the checking of pressure and to add more air if

necessary.

If the heating system is on the lower spectrum of use then the diaphragm

will be pushed against the water inlet. As the pressure increases the

diaphragm will move to increase the pressure on the air. Once

compressed the air will

cushion the pressure

and relieve it, in

essence, protecting the

system.

An 18 Litre

Expansion Vessel

comes as standard with

the HP200 model.

Expansion tank included to

the left.


88

4.1.11 Pressure Gauge

As the name suggests the pressure gauge is fitted onto the system to

monitor the pressure build-up within the circuit. It gives a graphical

indication of the pressure within both the circuit and the cylinder.

If the pressure was to get to much it could damage the system

immensely and cause huge financial strain on the client.

Normal working pressure would be 1 bar. A gauge measuring up to 4 bar

should be sufficient.


89

4.1.12 Automatic Air Vent

An automatic air vent is fitted at the highest point in the system. With out

system as we are using 6m2 (Two 3m2 system) we would need to include

two AAV’s to ensure safety.

An Automatic Air Vent purges air pockets from the system that may

otherwise develop in liquid at high points within the circuit.

The manufacturer recommends that with evacuated tube collectors the

AAV’s should be located on opposite ends of the collector’s manifolds.

The fitting used for this installation will be a 22mm

Spirax Sarco Solid Brass AAV.


90

4.1.13 Drain Valve

A drain valve is used to drain unwanted liquid from the storage cylinder.

Should a full drain of the system be needed this valve can be used to do

this as it must be placed at the lowest point on the system.

As with the other fittings a 22mm valve will be used in this system

installation.

4.1.14 Pressure Relief Valve

The pressure relief valve is an essential part of the safety components in

the solar thermal system.

Should the pressure in the system increase to an unmanageable level the

pressure relief valve will open to relieve this.

The PRV should have a minimum pressure

relief of 3 bar. But for this installation we

will be setting the pressure relieve to 6 bar.

The valve must be positioned so that there

is no restriction of flow between it and the

solar thermal collectors.


91

4.1.15 Thermostatic Mixing Valve

The TMV is a valve which mixes hot water with cold water from the mains

feed to ensure a safe output temperature for the clients use.

As it is common practice to store hot water above 60° Celsius the need

for the TMV is quite clear. For comfortable use of the hot water provided

from the solar thermal system it is recommended to keep the water

temperature below 50° Celsius (Max 48° Celsius) as temperatures above

this can cause scalding.

Installing a Thermostatic Mixing Valve can ensure that water is delivered

at a comfortable temperature and it protects against legionnaires disease.

For this installation the ProMix® 22-2 is to be

used as it provides extreme stability of mixed

water temperature even under varying

conditions. It has a high flow design and can

handle dynamic pressure.


92

4.1.16 Non Return Valve

Non return valves are used to prevent backwards flow of water and the

circulation of fluid when the pump is not active.

For example, at night, when the storage cylinder is hotter than the

collector the heat will try to flow in the direction of the solar collector. The

non-return valve prevents this from happening.


93

4.1.17 Immersion Heater

As mention before, all water should be heated to above 60° Celsius to

prevent legionnaire’s disease. In order to ensure this an immersion heater

can be used.

This should be placed inside the storage cylinder as an back up to the

solar thermal collectors.


94

5.0 Technical Calculations / System

Components Sizing


95

5.0.1 Collector Area

The sizing of the collector area is one of the most important factors when

designing a solar thermal system.

The collector aperture area will determine how much energy we can

extract from the sun.

There are five factors when calculating the size of the collector array.

1. How many people require hot water (Usage)

2. Contribution of solar energy to the hot water load

3. Geographic Location

4. Orientation and Slope of the roof

5. Type of collector being used.

Efficiency is also a factor when sizing the array. The collector area and the

solar fraction (ratio of energy supplied by the sun as opposed to the

required energy) also play a part.


96

The installer has to be careful when sizing the array as an oversized or

even undersized array can damage the overall efficiency of the system.

A high solar fraction will result in a higher temperature but a lower

yield of solar irradiation.

An oversized system will result in this higher solar fraction and

hence lower yield

An undersized system will result in low solar fraction and a higher

yield

A balance between these two is an ideal system.

The client is based in Ireland therefore a solar fraction of 55-60% is

normal. It has been assumed to be 60%

Above is a graphical representation of the previous summary.


97

5.0.2 Hot Water Demand

The amount of energy needed to heat the daily hot water demand is

shown below.

QHW = Volume of Daily DHW x Cw x

(ΔT)

Summary:

QWH – Daily Hot Water Demand

DHW – Domestic Hot Water

Cw – The Specific Heat Capacity of Water (This is

1.16 Wh/kgK or 4180 J kg-1 K-1)

ΔT – The Temperature Difference between

Incoming Cold and Required Hot Water

Calculation of the hot water demand is shown

below.

DHW = 300 Litres

Cw = 1.16Wh/kgK


98

Incoming Water Temp = 9.5° Celsius

Required Water Temp = 60° Celsius

Therefore:

300 x 1.16 x 50.5° = 17.574


99

5.0.3 Sizing of Collector Array

The formula for sizing the collector array is shown below:

This can be broken down to become the following:

No. of Days in Use – 365

Hot Water Heat Req – 17.574

Solar Fraction (Ireland) – 60%

ED = 384870.6

Yearly Irradiance (Dublin) – 949

Av. System Eff. – 73.0 (assumption)

SD = 69277

So if

then

= 5.6m2

If a 5.6m2 size array is needed to heat 300 litres of water we will need a

6m2 system (2 x 3m2) Therefore a 60 tube system is to be

installed for the client.


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5.0.4 System Flow Rate

Kingspan recommend that a flow rate of no less than 60 Ltr/hour/m2 be

used for pipe sizing in their Thermomax design guide.

This being said; the volumetric flow rate should be sized to ensure that it

is large enough to cool the solar collector sufficiently. This will result in

higher system efficiencies.

The formula to determine flow rate is shown below:

m = Volumetric flow rate

Q = Solar irradiance x collector efficiency W/m2

Cgw = Specific heat capacity of solar liquid. (Tyfocor LS = 0.98 Wh/kg K)

ΔӨ= 10 K

Solar Irradiance – 949

Collector Efficiency – 0.73

Specific heat capacity of solar liquid - 0.98

ΔӨ – 10 K

Therefore M = 70.7 Ltrs/m2h

Flow rate per tube =

= 1.18(m per min) x

60(tubes) = 7.08 ltrs/min


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5.0.5 Pipe Sizing

The formula to determine the inside diameter of the pipe work is shown

below:

Φi= 4.6

Φi – Internal Diameter

Vs – System Flow Rate

V – Velocity of Fluid (m/s)

Therefore:

Φi= 4.6

= 20.4mm

The internal pipe size we have calculated is 20.4. The manufacturer

recommends a 22mm pipe sizing for a 6m2 array so we will use this size.


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5.0.6 Pump Sizing

When sizing a pump we need to take into account the flow rate and the

head height of our array.

We have calculated that the flow rate for our system is 7.08 ltrs/min. This

will work out at 0.118ltrs/sec. From the chart below we can determine

which pump setting should be used.

It should be noted that a lot of installers set the pump setting to speed 3

as standard. This can be wasteful and unnecessary costly. Proper care

and careful calculations should be used when determining the pump

speed setting.

The above image is the speed setting graph for the KSP0020


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As we can see that as we have a head height of 7 meters and a flow rate

of .118ltrs/second we should have the pump on speed setting 2. The

pump being used for this installation is the KSP0020.


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5.0.7 Expansion Vessel Sizing

The expansion vessel can only be determined once we know the

temperature rise expected; charge and blow off pressures and also the

amount, or volume of heat transfer liquid that will be in the system. The

expansion vessel is essential to the system as a whole. It protects against

pressure rises and increased volumes.

The following formula determines that sizing of an expansion vessel:

Vev – Expansion Vessel Size

Vv – Safety Seal

Vd – Collector Volume

– Expansion Co-efficient of Heat Transfer Liquid

Pe – Safety Valve Rating -10%

Po – Minimum Working Pressure

Vv – 3 Litres (Recommended)

Vd – 3.4

– 0.085 (0.085 x 100/1 = 8.5%)

Pe – 5.4 + 1 = 6.4

Po – 6.4 – 3.9 = 2.5

A 30L Expansion Vessel is required.


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6.0 Stagnation Prevention


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6.0 Stagnation Prevention

Although the HP 200 System has in place a Temperature Snap to prevent

temperature rising above 135°Celsius one should understand it is

important to understand how to prevent stagnation.

Stagnation is something that should be avoided at all costs.

Temperatures in excess of 170° Celsius over a long period of time will

cause stagnation of the heat transfer fluid within the system. The Tyfocor

will degrade and its inhibitor properties also. This is evident by a brown

colour appearing rather than the pink colour it should be.

The solution should be tested each year and if necessary it should be

replaced.

It is possible to do this with a refractometer and some ph paper.

Stagnation can occur for a number of reasons such as:

Oversized Systems

Undersized expansion vessels

Air Locks within the System

Poor Set Up of the System

Prolonged Periods of Low Hot Water Demand

To prevent this, the manufacturer supplies a range of options. Heat can

be dissipated through an emitter such as a radiator.

Kingspan option A (Thermomax Design Guide) provides a system which

monitors the system and will dissipate heat through a radiator that is

connected on the solar side of the cylinder.

The control panel has several options such as stagnation prevention and a

thermostat that monitors temperature levels.


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Should the temperature rise above a preset level (usually 80° Celsius)

that heat will be diverted out through the radiator until the temperature is

reduced to a set level (usually 60° Celsius).


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7.0 Working at Height Risk Assessment


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7.0 Working at Height and Risk Assessment

Working at height can always be a dangerous activity for any installer.

While undertaking this installation we must be vigilant and respect the

dangers associated with it.

Regulations state that we must carry out a risk assessment on the site

before starting work. Arrangements must be put in place for the

following:

Eliminating or minimising risks from working at height

Safe systems for selecting suitable working equipment

Avoid the risk if not working at height if possible. (This isn’t

possible in this installation)

Safe systems of work for organising and performing work at

height

Safe systems for protecting people from the consequence of

working at height

The regulations and guidance’s outline practice for safe work at

height.

Falls should be prevented where at all possible. Especially when it is not

practicable to avoid working at height.

If this is the case you a required to take suitable and reasonable steps to

ensure the safety or the installers while working at height.

This is includes selecting the most suitable working equipment. This must

be done in accordance with regulations.

If steps cannot be put in place to prevent working at height an

investigation into the consequences must be carried out. This includes

taking measure to:

Minimising the height (if possible)


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Erecting guard rails on scaffolding

Safety harnesses should also be considered

Priority should be given to safety rails over safety harnesses as

prevention of a fall should be considered before protection during a fall.

Within the regulations you are required to do the following:

Follow the hierarchy of safe working at height regulations

Assess the risk to help you decide how to work safely

Make sure the installer working at height is responsible and

competent

Organise and plan work according to external risks such as weather,

time of day and possible emergencies

Manage risks from working on or around fragile surfaces

Beware of falling objects

Make use of appropriate work equipment

Inspect the place of work and observe the working equipment

regularly.

These are the requirements of that must be observed when installing a

Solar Thermal System.


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8.0 References

Material Type Author Reference List Accessed

PDF Kingspan Ltd. Thermomax Design Guide Apr-11 PDF Kingspan Ltd. Thermomax HP200 Apr-11 PDF Kingspan Ltd. Thermomax Leaflet Apr-11

PDF AEROLINE TUBE SYSTEMS BAUMANN GMBH Product Range Apr-11

PDF Tyforop Chemie GMBH Tyfo Data Apr-11 PDF Kingspan Ltd. Thermomax Installation Guide Apr-11

PDF Alternative Energy Ireland Brochure 2009 Apr-11 PDF Promix Promix 22-2 Apr-11

Website AEROLINE TUBE SYSTEMS BAUMANN GMBH http://www.tubesystems.com/ Apr-11

Website Pipeline Seal & Insulator, Inc. http://www.linkseal.com/ Apr-11 Website Spirax Sarco http://www.spiraxsarco.com/ie/ Apr-11 PDF Thorlux Lighting Ltd. Solow T5 Smart Mar-11 PDF Thorlux Lighting Ltd. Solow XL Smart Mar-11 PDF Thorlux Lighting Ltd. Juno Exterior Light Mar-11 PDF Thorlux Lighting Ltd. XL-Five Prismatic Mar-11 PDF Thorlux Lighting Ltd. CL-Five Mar-11 PDF Thorlux Lighting Ltd. Micro Bloc Mar-11 PDF Thorlux Lighting Ltd. Prismalux Mar-11

PDF Thorn Lighting Ltd. Base LED Mar-11 PDF Thorn Lighting Ltd. Jupiter II Mar-11 PDF Thorlux Lighting Ltd. Light Management System Mar-11 PDF Thorlux Lighting Ltd. Light Management System - POD Mar-11 PDF CIBSE Lighting Guide Mar-11 PDF Francis Rhubinstein Highbay lighting guide Mar-11 Website SEAI www.seai.ie Mar-11 Website ESB www.ESB.ie Mar-11 Website Phillips http://www.lighting.philips.ie/ Mar-11 Website Osram http://www.osram.com.sg/osram_sg/ Mar-11

http://www.tubesystems.com/

http://www.seai.ie/

http://www.esb.ie/

http://www.osram.com.sg/osram_sg/

Karl Phelan - Electrical Lighting Design & Solar Thermal Hot Water Installation

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